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5 th Largest Frozen brand and still Growing

Aunt Bessie’s Recipe To Optimize Packaging John Hendy Commercial Director Tryton Foods Ltd. 5 th Largest Frozen brand and still Growing. Tryton Foods: The Home of Aunt Bessie’s.

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5 th Largest Frozen brand and still Growing

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  1. Aunt Bessie’s Recipe To Optimize PackagingJohn Hendy Commercial Director Tryton Foods Ltd

  2. 5th Largest Frozen brand and still Growing

  3. Tryton Foods:The Home of Aunt Bessie’s • Brand value £168m at RSP • One of the Fastest Growing brands in frozen • Top two selling products – Baked Yorkshires • Roast Potatoes • Fastest selling traditional hot dessert • Apple pie • Penetration 58% of all households • Consumer awareness 96% • Brand Managed through Own Manufacture; Licensing and Co-packing

  4. Aunt Bessie’s Range

  5. Packaging Optimisation Context • Brand led packaging designs, often over specified • Light products, carrying around lots of air. • Packaging specifications broad to allow for inaccuracies in process capability. • Low cube utilization of vehicles. = Opportunities To Improve

  6. Project Based Approach to Optimizing. Reduce • Streamline: Packaging reduction • Freeloader: Fill every vehicle Recycle • Basic Separation

  7. StreamlineWhat packaging can we remove without impacting on the product? • Tray removal / redesign • Film re-size / re-specify • Case resize / re-grade / remove

  8. FreeloaderMaximise the amount of product on each vehicle? • Filling the Cube. • Maximize the number of cases per pallet • Minimize the headroom in the case • Maximize the case size • Maximise the pallet height / fill • Maximizing the Cube. • Use double deck trailers where possible if not weight constrained.

  9. Results from optimisation • Over £750k/yr of reduced packaging costs • 400tns/yr less packaging • 500 000 less road miles travelled to carry the same product. • 10% less pallet spaces required to store same volume

  10. Clear Financial Rational Increased Scale Optimize Packaging Reduced Cost Sales Growth Investment in Brand Releases money for Investment

  11. Lots of small projects add up • Removal of 2” tray • Removal of 7” tray • Redesign of 7” twin pack tray • Reconfiguration of Ready to Bake case layout • Removal of Pancake tray • Re sizing all film specs • Reducing case head room • Changing case board specification • Adding layers to pallets • Reconfiguring pallet layouts to increase cases / layer • Taking air out of bagged product • Negotiating customer specific case sizes and pallet sizes • Load / order planning to maximise double deck trailer utilisation

  12. Right Project Team Essential • Good leadership • Board level sponsorship and profile • Cross functional commitment (esp Marketing) • Involve supplier experts • ‘Doers’ not talkers • Empowerment to make trade offs • Quick decisions with assumption to change

  13. Re-cycle:Separation of waste streams Secret Weapon

  14. Separation of waste: Basic’s get results • Collection bins for each packaging types • Bins in the right place • Clear responsibility for removal and organising recycling • Purpose designed baling and storage areas for packaging waste • Staff awareness and training

  15. Result 100% of all packaging waste is now recycled

  16. Final Thoughts • Project activities need to turn into the everyday ways of working • Progress isn’t free and required investment (Time and Capital) • Tightening packaging specifications, highlights process variations • Persistence is essential to get results

  17. Thank You

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